PREDATOR 59190-UPC 8750 Watt Inverter Generator Owner’s Manual
- June 9, 2024
- Predator
Table of Contents
59190-UPC 8750 Watt Inverter Generator
Owner’s Manual & Safety Instructions
Save This Manual Keep this manual for the safety warnings and precautions, assembly,
operating, inspection, maintenance and cleaning procedures. Write the product’s serial number in the
back of the manual (or month and year of purchase if product has no number). Keep this manual and the
receipt in a safe and dry place for future reference.
22e
8750 WATT
INVERTER
GENERATOR
7000 RUNNING WATTS 8750 MAX STARTING WATTS
Visit our website at: http://www.harborfreight.com Email our technical support
at: [email protected]
Email our engine support at: [email protected]
59190
Using a generator indoors CAN KILL YOU IN MINUTES.
Generator exhaust contains carbon monoxide. This is a poison you cannot see or
smell.
Do not use in trailers, truck beds, or tents.
NEVER use inside a home or garage, EVEN IF doors and windows are open.
Only use OUTSIDE and far away from windows, doors, and vents.
DANGER
Use at least 20 feet away from people, animals, and structures with exhaust
pointed away.
20
20 20
20 20
When unpacking, make sure that the product is intact and undamaged. If any
parts are missing or broken,
please call 1-888-866-5797 as soon as
possible.
Copyright© 2021 by Harbor Freight Tools®. All rights reserved. No portion of
this manual or any artwork contained herein may be reproduced in any shape or
form without the express written consent of Harbor Freight Tools. Diagrams
within this manual may not be drawn proportionally. Due to continuing
improvements, actual product may differ slightly from the product described
herein.
Tools required for assembly and service may not be included.
Read this material before using this product. Failure to do so can result in serious injury. SAVE THIS MANUAL.
SaFEty
table of contents
Safety ………………………………………………… 2 Setup …………………………………………………. 6 Specifications ……………………………………… 6 Operation…………………………………………… 13
Maintenance ………………………………………. 20 Parts List and Diagram ………………………… 26 Warranty ……………………………………………. 32
WarninG SyMBOLS anD DEFinitiOnS
This is the safety alert symbol. It is used to alert you to potential personal
injury hazards. Obey all safety messages that follow this symbol to avoid
possible injury or death.
Indicates a hazardous situation which, if not avoided, will result in death or serious injury.
Indicates a hazardous situation which, if not avoided, could result in death or serious injury.
Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.
Addresses practices not related to personal injury.
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iMpOrtant SaFEty inStructiOnS
SaVE tHESE inStructiOnS
This manual contains important instructions that should be followed during
installation and maintenance of the Generator and any batteries.
Set up precautions
1. This unit is to be installed so that access is restricted to only
qualified service personnel who have been instructed of the reasons for the
restrictions applied to the location and about any precautions that must be
taken. Access shall be through the use of a special tool, or lock and key, or
other means of security and shall be controlled by the authority responsible
for the location.
2. Gasoline fuel and fumes are flammable, and potentially explosive. Use
proper fuel storage and handling procedures. Do not store fuel or other
flammable materials nearby.
3. Have multiple ABC class fire extinguishers nearby.
7. Connections for standby power to a building electrical system must be made
by a qualified electrician. The connection must isolate the Generator power
from utility power, and must comply with all applicable laws and electrical
codes.
8. Wear ANSI-approved safety goggles, heavy-duty work gloves, and dust
mask/respirator during set up.
9. Use only lubricants and fuel recommended in this manual.
10. A transfer switch should be installed by a licensed electrician in
compliance with all applicable laws and electrical codes.
4. Operation of this equipment may create sparks that can start fires around
dry vegetation. A spark arrestor may be required. The operator should contact
local fire agencies for laws or regulations relating to fire prevention
requirements.
5. Set up and use only on a flat, level, well-ventilated surface.
6. All connections and conduits from the Generator to the load must only be
installed by trained and licensed electricians, and in compliance with all
relevant local, state, and federal electrical codes and standards, and other
regulations where applicable.
11. Improper connections to a building electrical system can allow electrical
current from the Generator to backfeed into the utility lines. Such backfeed
may electrocute utility company workers or others who contact the lines during
a power outage, and the Generator may explode, burn, or cause fires when
utility power is restored. Consult the utility company and a qualified
electrician if intending to use the Generator for back up power.
12. Do not operate the Generator before grounding. The Generator must be
earth-grounded in accordance with all relevant electrical codes and standards
before operation.
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13. Install carbon monoxide alarm(s) with battery backup in nearby buildings according to manufacturer’s instructions.
Operating precautions
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carBOn MOnOXiDE HaZarD
using a generator indoors can
KiLL yOu in MinutES.
Generator exhaust contains carbon
monoxide. This is a poison you cannot
see or smell.
3. Never use a generator indoors, including in garages, basements,
crawlspaces and sheds. Opening doors and windows or using fans will NOT
prevent carbon monoxide build up in the home.
4. When using generators, keep them outdoors and far away from open doors,
windows, and vents to avoid toxic levels of carbon monoxide from building up
indoors.
NEVER use inside a home or garage, EVEN IF doors and windows are open.
5. If you start to feel sick, dizzy, or weak while using a generator, get to
fresh air right away. The carbon monoxide from generators can quickly lead to
full incapacitation and death.
6. Keep children away from the equipment, especially while it is operating.
7. Keep all spectators at least six feet from the Engine during operation.
8. Do not touch engine during use. Let engine cool down after use.
Only use OUTSIDE and far away from windows, doors, and vents.
2. carBOn MOnOXiDE SHutOFF
DanGEr! tO prEVEnt SEriOuS inJury anD DEatH FrOM carBOn MOnOXiDE inHaLatiOn:
the carbon Monoxide sensor is an additional layer of protection only. Do not
use the Generator in any area or situation that will allow carbon monoxide to
accumulate.
· FLASHING RED LIGHT: Dangerous levels of carbon monoxide gas have built up
and generator will shutoff. Leave immediately until area has aired out. Move
Generator to well-ventilated area before operation.
· FLASHING YELLOW LIGHT: Carbon monoxide sensor malfunction. Sensor needs
service. Do not use the Generator until the sensor is working properly. For
technical questions, please call
1-888-866-5797. NOTE: Yellow light
flashes once after starting to indicate passing selfcheck and is functioning
normally.
carbon Monoxide sensor must only be serviced by qualified technician to
restore it to original settings. Do not modify or tamper with the carbon
Monoxide sensor. not following these instructions can result in death or
serious injury due to carbon Monoxide sensor malfunction.
9. Never store fuel or other flammable materials near the engine.
10. Fire Hazard! Do not fill gas tank while engine is running. Do not operate
if gasoline has been spilled. Clean spilled gasoline before starting engine.
Do not operate near pilot light or open flame.
11. If the plugged in product operates abnormally or unusually slow,
immediately stop using the Generator as a power source. Always read and adhere
to the instruction manual of the product to be powered, to make sure that it
can be safely and efficiently powered by a portable generator.
12. Before connecting an appliance or power cord to the Generator: Make sure
that it is in good working order. Faulty appliances or power cords can create
a potential for electrical shock.
13. Do not exceed the maximum power rating of the Generator. Make sure that
the total electrical rating of the all of the tools or appliances plugged into
the Generator at the same time does not exceed that of the Generator. Check
that the startup surge will not be beyond the limit of the Generator. Power
levels between rated and maximum may be used for no more than 30 minutes.
14. Avoid substantially overloading which will trip the circuit breaker.
Exceeding the time limit for maximum power operation or slightly overloading
the Generator may not switch the circuit breaker or circuit protector OFF, but
will shorten the service life of the Generator.
ITEM 59190
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15. Do not attempt to connect or disconnect load connections while standing
in water, or on wet or soggy ground.
16. Do not touch electrically energized parts of the Generator and
interconnecting cables or conductors with any part of the body, or with any
non-insulated conductive object.
17. Connect the Generator only to a load or electrical system (120 volt or
240 volt) that is compatible with the electrical characteristics and rated
capacities of the Generator.
18. GFci prEcautiOnS Test Ground Fault Circuit Interrupter (GFCI) receptacles
before each use as follows: a. Disconnect all devices from the Generator. b.
Start the engine. c. Press Test button on receptacle to trip the GFCI device.
d. The Reset button should extend, cutting off electricity to the receptacle.
e. If above test fails, do not use receptacle until it is repaired or
replaced. f. Press Reset button in for use.
Refer to Grounding on page 10.
19. Insulate all connections and disconnected wires.
20. Guard against electric shock. Prevent body contact with grounded surfaces
such as pipes, radiators, ranges, and refrigerators.
21. Only use a suitable means of transport and lifting devices with
sufficient weight bearing capacity when transporting the Generator.
22. Secure the Generator on transport vehicles to prevent the tool from
rolling, slipping, and tilting.
23. Industrial applications must follow OSHA requirements.
24. Do not leave the Generator unattended when it is running. Turn off the
Generator (and remove safety keys, if available) before leaving the work area.
25. The Generator engine can produce high noise levels. Prolonged exposure to
noise levels above 85 dBA is hazardous to hearing. Always wear ear protection
when operating or working around the gas engine while it is operating.
26. Wear ANSI-approved safety glasses, hearing protection, and NIOSH-approved
dust mask/respirator during use.
27. People with pacemakers should consult their physician(s) before use.
Electromagnetic fields in close proximity to a heart pacemaker could cause
pacemaker interference or pacemaker failure. Caution is necessary when near
the engine’s magneto or recoil starter.
28. Use only accessories that are recommended by Harbor Freight Tools for
your model. Accessories that may be suitable for one piece of equipment may
become hazardous when used on another piece of equipment.
29. Do not operate in explosive atmospheres, such as in the presence of
flammable liquids, gases, or dust. Gasoline-powered engines may ignite the
dust or fumes.
30. Keep grounded conductive objects, such as tools, away from exposed, live
electrical parts and connections to avoid sparking or arcing. These events
could ignite fumes or vapors.
31. Stay alert, watch what you are doing and use common sense when operating
this piece of equipment. Do not use this piece of equipment while tired or
under the influence of drugs, alcohol or medication.
32. Dress properly. Do not wear loose clothing or jewelry. Keep hair,
clothing and gloves away from moving parts. Loose clothes, jewelry or long
hair can be caught in moving parts.
33. Parts, especially exhaust system components, get very hot during use.
Stay clear of hot parts.
34. Do not cover the Generator or its engine during operation.
35. Keep the Generator, its engine, and surrounding area clean at all times.
Keep generator at least 5 feet from combustible objects.
36. Do not smoke, or allow sparks, flames, or other sources of ignition
around the equipment, especially when refuelling.
37. Use the Generator, accessories, etc., in accordance with these
instructions and in the manner intended for the particular type of equipment,
taking into account the working conditions and the work to be performed. Use
of the equipment for operations different from those intended could result in
a hazardous situation.
38. Do not operate the Generator with known leaks in the engine’s fuel
system.
39. When spills of fuel or oil occur, they must be cleaned up immediately.
Dispose of fluids and cleaning materials as per any local, state, or federal
codes and regulations. Store oil rags in a bottom-ventilated, covered, metal
container.
40. Keep hands and feet away from moving parts. Do not reach over or across
Generator while operating.
41. Before use, check for misalignment or binding of moving parts, breakage
of parts, and any other condition that may affect the Generator’s operation.
if damaged, have the Generator serviced before using. Many accidents are
caused by poorly maintained equipment.
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42. Use the correct generator for the application. Do not modify the
generator or its engine, and do not use the generator for a purpose for which
it is not intended.
43. Extension Cord – Make sure your extension cord is in good condition. When
using an extension cord, be sure to use one heavy enough to carry the current
your product will draw. An undersized extension cord will cause a drop in line
voltage resulting in loss of power and overheating.
The table below shows the correct cord size to use depending on cord length
and nameplate ampere rating. If in doubt, use the next heavier gauge. The
smaller the gauge number, the heavier the cord.
rEcOMMEnDED MiniMuM WirE GauGE FOr EXtEnSiOn cOrDS
currEnt (aMpS)
Load @ 120V
(WattS)
Load @ 240V
(WattS)
0 ~ 50 ft
50 ~ 75 ft
75 ~ 100 ft
2
240
480
18 AWG
4
480
960
18 AWG
16 AWG
6
720
1440
18 AWG
16 AWG
14 AWG
8
960
1920
16 AWG
12 AWG
10
1200
2400
16 AWG
14 AWG
12 AWG
15
1800
3600
14 AWG
12 AWG
10 AWG
20
2400
4800
12 AWG
10 AWG
25
3000
6000
12 AWG
10 AWG
8 AWG
30
3600
7200
10 AWG
8 AWG
35
4200
8400
8 AWG
6 AWG
40
4800
9600
6 AWG
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ITEM 59190
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Service precautions
1. Before service, maintenance, or cleaning: a. unplug all devices from the
Generator. b. turn the engine switch to its “OFF” position. c. allow the
engine to completely cool. d. Disconnect the negative (-) battery terminal. e.
then, remove the spark plug cap from the spark plug.
2. Keep all safety guards in place and in proper working order. Safety guards
include muffler, air cleaner, mechanical guards, and heat shields, among other
guards.
3. Make sure the Engine Switch is in its “OFF” position before moving the
Generator and before performing any service, maintenance, or cleaning
procedures on the unit.
4. Keep all electrical equipment clean and dry. Replace any wiring where the
insulation is cracked, cut, abraded, or otherwise degraded. Replace terminals
that are worn, discolored, or corroded. Keep terminals clean and tight.
5. Do not alter or adjust any part of the equipment or its engine that is
sealed by the manufacturer or distributor. Only a qualified service technician
may adjust parts that may increase or decrease governed engine speed.
6. Wear ANSI-approved safety goggles, heavy-duty work gloves, and dust
mask/respirator during service.
7. Maintain labels and nameplates on the equipment. These carry important
information. If unreadable or missing, contact Harbor Freight Tools for a
replacement.
8. Have the equipment serviced by a qualified repair person using only
identical replacement parts. This will ensure that the safety of the equipment
is maintained. Do not attempt any service or maintenance procedures not
explained in this manual or any procedures that you are uncertain about your
ability to perform safely or correctly.
9. Store equipment out of the reach of children.
10. Follow scheduled engine and equipment maintenance.
GFci protection:
This Generator is equipped with two 3-Prong, duplex 120V ground fault circuit
interrupter (GFCI) receptacles. These outlets provide additional protection
from the risk of electric shock. Should replacement of the receptacles become
necessary, use only identical replacement parts that include GFCI protection.
refueling:
1. Do not refill the fuel tank while the engine is running or hot.
2. Do not smoke, or allow sparks, flames, or other sources of ignition around
the equipment, especially when refuelling.
3. tO prEVEnt FuEL LEaKaGE anD FirE HaZarD, Do not overfill with fuel. Fill
with fuel according to the Fuel Level information below the Specification
chart for your model.
4. Do not fill fuel tank to the top. Leave a little room for the fuel to
expand as needed.
5. Refuel in a well-ventilated area only.
6. Wipe up any spilled fuel and allow excess to evaporate before starting
engine. to prevent FirE, do not start the engine while the smell of fuel hangs
in the air.
Battery Service:
1. Servicing of batteries are to be performed or supervised by personnel
knowledgeable of batteries and the required precautions. Keep unauthorized
personnel away from batteries.
2. When replacing battery, use the following type battery: 12V, 1.6Ah Lithium
Iron Phosphate (LiFEPO4) type.
3. CAUTION Do not dispose of battery or batteries in a fire. The battery is
capable of exploding. Batteries must be recycled or disposed of properly.
4. CAUTION Do not open or mutilate the battery. Released electrolyte has
been known to be harmful to the skin and eyes and to be toxic.
5. CAUTION A battery presents a risk of high short circuit current. The
following precautions are to be observed when working on batteries: a. Remove
watches, rings, or other metal objects. b. Use tools with insulated handles.
c. Do not lay tools or metal parts on top of batteries.
SaVE tHESE inStructiOnS.
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ITEM 59190
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Functional Description
Specifications
Output
Generator Battery for electric start
Electrical Receptacle
Engine
Displacement Engine Type Cooling System
Fuel
Type Capacity
Engine Oil
Type SAE
Capacity
Spark Plug
Type Gap
Valve Clearance Intake/Exhaust
Run Time @ 25% load
Operational Volume
120/240VAC, 60Hz, 58.3 / 29.2 A, 1 Phase 7,000 Running Watts (8,750 max.
starting Watts) 12VDC, 8.3A 5V USB, 3.1A
12V, 1.6AH Lithium Iron Phosphate (LiFEPO4)
Two 3-Prong, duplex NEMA #5-20 120V GFCI One 4-Prong, NEMA #L14-30 twistlock
120V/240V One DC Outlet 12VDC 2X USB-A Ports
420cc
Horizontal Single Cylinder 4 stroke OHV
Forced air cooled
87+ octane stabilizer treated unleaded gasoline
5.94 Gallon / 22.50 Liter
10W30 above 32°F 5W30 at 32°F or below
1.1 Quart NHSP® / LG F7TC
0.028″0.031″
0.0019 – 0.0039
15.1 hr.
75 dB(A) @ 21 ft., 25% load
The emission control system for this Generator’s Engine is warranted for standards set by the U.S. Environmental Protection Agency and by the California Air Resources Board (also known as CARB). For warranty information, refer to the last pages of this manual.
components and controls
Fuel cap
control panel
Fuel Gauge
Fuel Valve
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Battery Holder
receptacles Oil Drain
Muffler Oil Fill
air cleaner
ITEM 59190
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Starter Handle
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components and controls (continued)
choke
Output indicators
Overload Low Oil
ac Overload reset
Digital Display
Mode Button
20a Breakers
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Start Switch
Dc Breaker
ESc throttle
cO Sensor Light
12V Dc receptacle
uSB ports
30a Breaker L14-30 receptacle
Ground
5-20r GFci receptacles
The following are descriptions of the controls on the power panel. Your
Generator has sockets to power your products with circuit breakers to protect
the voltage flow.
Start
i O
1. Engine Switch: Used to start and stop the Engine.
2. ac receptacles: The Generator contains several AC Receptacles to power
tools and equipment.
On
OFF
3. circuit Breakers: The circuit breaker protects the Generator from
overloading. The rating of the breaker and the load it protects are marked
near the breaker. Should any of the Circuit Breakers trip, the Generator will
stop the electricity output. If this happens, unplug all loads from the
Generator. Then, turn the tripped Circuit Breaker to ON and re-attach loads
gradually. note: For pushtype Circuit Breakers allow a few minutes for
cooldown before resetting.
4. 12 VDc receptacle: 12 VDC Receptacle provides a power source for 12 volt
DC items.
rESEt
tESt rESEt
tESt
a. 3-prong, duplex 120 volt GFci receptacle (nEMa #5-20)
b. 4-prong, twistlock, 120/240 volt receptacle (nEMa #L14-30)
5. Grounding terminal: Prior to each use, set up the ground wire (not
included) connection to the Grounding Terminal to properly ground the
Generator. Refer to Grounding on page 10 for instructions on grounding the
Generator.
6. Digital Display: Press the Mode Button to cycle through the Display’s
functions:
· Voltage (Displays U + voltage reading. Example: “U120”)
· Frequency (Displays F + frequency reading. Ex.: “F60”)
· Current session runtime
· Total (accumulated) runtime
WarninG! tO prEVEnt SEriOuS inJury: Connect tools and equipment only to the Receptacle (120 volt or 240 volt) that is compatible with the electrical characteristics and rated capacities of the tools and equipment being used.
note: Every 50 hours, a blinking maintenance reminder will appear on the screen (P050, P100, P150, etc.) See Page 18 for maintenance schedule. To clear a maintenance reminder, press and hold the Mode Button for 5 seconds.
OpEratiOn
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initial tool Set up/assembly
read the EntirE iMpOrtant SaFEty inFOrMatiOn section at the beginning of this
manual including all text under subheadings therein before set up or use of
this product.
tO prEVEnt SEriOuS inJury: Operate only with proper spark arrestor installed.
Operation of this equipment may create sparks that can start fires around dry
vegetation. a spark arrestor may be required. the operator should contact
local fire agencies for laws or regulations relating to fire prevention
requirements.
At high altitudes, the engine’s carburetor, governor, and any other parts that
control the fuel-air ratio will need to be adjusted by a qualified mechanic to
allow efficient high-altitude use and to prevent damage to the engine and any
other devices used with this product.
note: For additional information regarding the parts listed in the following
pages, refer to the Assembly Diagram near the end of this manual.
Wheel Kit assembly
Install the included wheel kit by following the instructions included with it.
installing the Wheels
1. Unpack and identify all parts.
2. Slide the Axle (11a) onto one
side of the compressor frame
and secure the Nut (14a)
11a
in place. Repeat on the
other side of the frame.
installing the Feet
3. Slide a Washer (10a),
a Wheel (12a), and
another Washer (13a)
onto an Axle and secure 9a
the Nut (9a) in place.
10a
Repeat on the other Axle. 14a
13a 12a 11a
1. Secure the Foot (18a)
15a
onto the bottom of the
Foot Support (16a) with a
Bolt (19a) and Nut (15a).
19a
2. Working on the opposite end of the Frame from the
wheels, align the holes in
16a
the frame with a Foot
15a
Support (16a) and secure
in place with two
18a
Bolts (17a) and Nuts (15a).
Repeat with the other Foot support.
17a 16a
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installing the Handle
1. Remove the Bolt (6a)
8a
holding the Handle (4a) to the
6a
Handle Seat (7a) before installing
the Handle Seat.
4. Align the Handle (4a) with the holes in the Handle Seat and secure in place with the Bolt (6a) and Nut (8a).
8a 6a
2. Holding the Handle Seat as shown at right, align the holes of the Handle
Seat (7a) with the holes on the generator frame on the same side as the Feet.
3. Secure in place with four Bolts (5a).
4a
5a 7a
5. Use the Pin (2a) to secure the handle in the raised or lowered position.
To lock raised
To lock lowered
Battery Setup instructions
All generators can be started using the recoil method. This Generator requires installation of a battery to operate the electric start feature. Connect the battery to the Generator engine:
1. Remove terminal covers from the battery, if installed.
2. Attach the positive (red) cable connector from the engine to the Positive
Terminal on the battery. Connect cable securely to prevent disconnection and
short circuits.
3. Attach the negative (black) cable connector to the negative battery
terminal.
note: This generator is equipped with a battery charging circuit specific to the installed battery type that will charge the battery when the generator is running. If battery needs charging during storage, make sure to use a charger that provides less than 1 Amp and voltage less than 14V. Do not overcharge. Unplug charger when battery is fully charged.
Grounding
The Generator must be properly grounded in accordance with all relevant
electrical codes and standards before operation. In many locations, local code
will not require this generator to be grounded when used with cord and plug
equipment plugged directly into the receptacles on the generator. However,
your local regulations may require the generator to be grounded. Contact a
licensed electrician or consult local authorities regarding local grounding
requirements. If grounding is required, have the unit grounded by a qualified
electrician if you are not qualified to do so.
General grounding instructions are as follows:
Use one of the following as the grounding electrode: pipe or conduit, minimum
¾ in. diameter, minimum 8 ft. long. If steel, it must have anti-corrosion
coating. rod, stainless steel or copper- or zinc-coated steel, minimum 5/8 in.
diameter, minimum 8 ft. long.
1. Drive electrode at least 8 ft. vertically into the ground.
a. If rock layer prevents vertical entry, drive at an angle not exceeding 45
degrees from vertical.
b. If rock layer prevents angle entry, bury electrode in horizontal trench at
least 30 in. deep.
2. The upper end of electrode must be protected if above ground level.
3. Connect a #6 AWG grounding wire (not included) from the Grounding Terminal
on the Generator Control Panel to the buried electrode.
For additional information on grounding methods, please see the National
Electrical Code.
nOticE: There is a permanent conductor between the portable generator inverter
module (Neutral Conductor) and the frame.
OpEratiOn
MaintEnancE
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remove the Shipping Brackets
to protect the Generator during shipping, Shipping Brackets have been
installed between the Engine and Frame. these brackets MuSt BE rEMOVED BEFOrE
adding oil or gasoline to the Generator. nOticE: DO nOt attempt to start
Generator without first removing the Shipping Brackets. Damage to the
Generator as a result of not removing the Brackets will void the warranty. 1.
BEFORE filling the Engine with oil or gasoline, tip the Generator onto its
recoil end. Tip onto the flattened
cardboard box the Generator came in or other protective surface so as to not
scratch the Frame. 2. Remove the Bolts from the orange Shipping Brackets.
Bolts and Shipping Brackets can be discarded.
Figure a: remove Both Shipping Brackets and Bolts 3. Tip the Generator
upright.
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Page 11
High altitude Operation above 3000 feet
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WarninG! tO prEVEnt SEriOuS inJury FrOM FirE: Follow instructions in a well-
ventilated area away from ignition sources. If the engine is hot from use,
shut the engine off and wait for it to cool before proceeding. Do not smoke.
nOticE Warranty void if necessary adjustments are not made for high altitude
use.
At high altitudes, the engine’s carburetor, governor, and any other parts that
control the fuel-air ratio will need to be adjusted by a qualified mechanic to
allow efficient high-altitude use and to prevent damage to the engine and any
other devices used with this product. The fuel system on this engine may be
influenced by operation at higher altitudes. Proper operation can be ensured
by installing an altitude kit at altitudes higher than 3000 ft. above sea
level. At elevations above 8000 ft, the engine may experience decreased
performance, even with the proper main jet. Operating this engine without the
proper altitude kit installed may increase the engine’s emissions and decrease
fuel economy and performance. The kit should be installed by a qualified
mechanic.
note: Not all Generator models have a Solenoid. Skip those steps if a Solenoid is not present.
1. Turn off the engine. 2. Close the fuel valve.
nuts Deflecting plate
3. Move the air cleaner housing aside to allow access to the carburetor: a. Loosen the knob and remove air cleaner cover.
Foam Filter
b. Remove the foam filter and deflecting plate.
c. Remove the nuts to allow the air cleaner housing to be moved aside.
4. Place a bowl under the fuel cup to catch any spilled fuel. 5. Unthread the screws holding the solenoid in place.
air cleaner Housing
cautiOn! Carburetor bowl may have gas in it which will leak upon removing the
solenoid/bolt.
6. Disconnect the solenoid and solenoid seal from the bolt.
air cleaner cover
7. Unthread the bolt holding the fuel cup.
8. Remove the bolt, Bolt Seal, fuel cup, Fuel Cup Seal and Main Jet from the body of the carburetor assembly. A carburetor screwdriver (not included) is needed to remove and install the Main Jet.
note: The mixing tube is held in place by the Main Jet and might fall out when
it is removed. If it falls out, replace it in the same orientation before
replacing the Main Jet.
9. Replace the Main Jet with the replacement Main Jet needed for your
altitude range (part 1a or 2a).
note: The Fuel Cup Seal and Bolt Seal may be damaged during removal and should
be replaced with the new ones from the kit.
10. Replace the Fuel Cup Seal (4a), fuel cup, Bolt Seal (3a), and bolt.
Tighten in place.
carburetor assembly
Fuel cup Seal
Mixing tube (might remain inside carburetor)
nOticE: Do not cross thread bolt when tightening. Finger tighten first and
then use a wrench to make sure the bolt is properly threaded.
11. Replace the solenoid and Solenoid Seal (5a), and tighten in place with
screws.
Main Jet Fuel cup
12. Reassemble the air cleaner and reattach all hoses to it.
Bolt Seal
13. Wipe up any spilled fuel and allow excess to evaporate before starting engine. To prevent FIRE, do not start the engine while the smell of fuel hangs in the air.
Bolt Solenoid Seal
High altitude Kit parts List – a
part
Description
Qty
1a Main Jet 3000-6000 ft. 1
2a Main Jet 6000-8000 ft. 1
3a Bolt Seal
1
4a Fuel Cup Seal
1
5a Solenoid Seal
1
Not present on some Generators
Solenoid Screws
Page 12
For technical questions, please call 1-888-866-5797.
ITEM 59190
OpEratiOn
MaintEnancE
SaFEty
SEtup
Operating instructions
read the EntirE iMpOrtant SaFEty inFOrMatiOn section at the beginning of this
manual including all text under subheadings therein before set up or use of
this product.
inspect tool before use, looking for damaged, loose, and missing parts. if any
problems are found, do not use tool until repaired.
Generator pre-Start checks
Inspect engine and equipment, looking for damaged, loose, and missing parts before set up and starting. If any problems are found, do not use equipment until fixed properly.
6. Thread the dipstick back in clockwise.
cautiOn! Do not run the engine with too little oil. The engine will be
permanently damaged.
checking and Filling Engine Oil
cautiOn! your Warranty is VOiD if the engine’s crankcase is not properly
filled with oil before each use. Before each use, check the oil level. Do not
run the engine with low or no engine oil. running the engine with no or low
engine oil WiLL permanently damage the engine.
1. Make sure the engine is stopped and is level.
2. Close the Fuel Valve.
3. Clean the top of the Dipstick and the area around it. Remove the Dipstick
by threading it counterclockwise, and wipe it off with a clean lint free rag.
checking and Filling Fuel
WarninG! tO prEVEnt SEriOuS inJury FrOM FirE: Fill the fuel tank in a well-
ventilated area away from ignition sources. if the engine is hot from use,
shut the engine off and wait for it to cool before adding fuel. Do not smoke.
1. Clean the Fuel Cap and the area around it.
2. Unscrew and remove the Fuel Cap.
3. If needed, fill the Fuel Tank to about 1 inch under the fill neck with 87
octane or higher unleaded gasoline that has been treated with a fuel
stabilizer additive. Follow fuel stabilizer manufacturer’s recommendations for
use.
Full level
Full level
4. Reinsert the Dipstick without threading it in and remove it to check the
oil level. The oil level should be up to the full level as shown above.
5. If the oil level is at or below the low mark add the appropriate type of
oil until the oil level is at the proper level. SAE 10W-30 oil is recommended
for general use. (The SAE Viscosity Grade chart on page 21 in the Service
section shows other viscosities to use in different average temperatures.)
note: Do not use gasoline containing more than 10% ethanol (E10). Do not use
E85 ethanol.
note: Do not use gasoline that has been stored in a metal fuel container or a
dirty fuel container. it can cause particles to enter the carburetor,
effecting engine performance and/or causing damage.
4. Then replace the Fuel Cap.
5. Wipe up any spilled fuel and allow excess to evaporate before starting
engine. To prevent FIRE, do not start the engine while the smell of fuel hangs
in the air.
OpEratiOn
MaintEnancE
ITEM 59190
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Page 13
SaFEty
using the Generator
Before Starting the Generator Engine
Before starting the engine: a. Follow the Set up instructions
to prepare the Generator. b. unplug all loads from the Generator. c. inspect
the Generator and engine. d. Fill the engine with the proper
amount and type of both stabilizer-treated fuel and oil.
Basic Generator use procedure See following pages for specific instructions
1. Check that the Generator can handle the wattage needed to power your
products.
2. Start the Engine, and allow the Engine and Generator to run and warm up
for five minutes after starting with no electrical load.
3. With the engine running, test GFCI receptacles before each use as follows:
a. Press Test button on receptacle to trip the GFCI device. b. The Reset
button should extend, cutting off electricity to the receptacle. c. If above
test fails, do not use receptacle until it is repaired or replaced.
Break-in period:
a. Breaking-in the engine will help to ensure proper equipment and engine
operation.
b. The break-in period will last about 25 hours of use. DO NOT exceed 75% of
the Generator’s rated capacity during this period.
d. Press Reset button in for use.
reset
Button
rESEt
tESt
tESt rESEt
test Button
120 Volt GFci receptacle
4. Plug in products.
5. When finished using the Generator, disconnect all electrical loads.
note: Do not allow Generator to run out of fuel with loads attached.
6. Turn off the Engine.
7. Allow the Generator and its Engine to completely cool. Then store the unit
in a clean, dry, safe location out of reach of children and other unauthorized
people.
iMpOrtant: After starting the engine, allow it to run at no load for five
minutes with no load after each start-up so that the engine can stabilize.
· Change the engine oil after this period.
Under normal operating conditions subsequent maintenance follows the schedule
explained in the MAINTENANCE section.
SEtup
OpEratiOn
MaintEnancE
Page 14
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ITEM 59190
SaFEty
Starting the Engine
1. To start a cold engine, pull the Choke Knob out to the START position. To
restart a warm engine, leave the Choke Knob in the RUN position.
2. Open the Fuel Valve.
SEtup
OpEratiOn
3. Put ESC Switch in off position.
4. For ManuaL Start
a. Turn the Engine Switch to ON.
Start
i O B. Grip the Starter Handle of the Engine loosely and pull it slowly
several times to allow the gasoline to flow into the Engine’s carburetor. Then
pull the Starter Handle gently until resistance is felt. Allow Cable to
retract fully and then pull it quickly. Repeat until the engine starts. Note:
Do not let the Starter Handle snap back against the engine. Hold it as it
recoils so it doesn’t hit the engine.
5. Allow the Engine to run for several seconds. Then, if the Choke Knob is in
the CHOKE position, move the Choke Knob very slowly to its RUN position.
For ELEctric Start
Turn the Engine Switch to START.
START
Start
i O
note: To prolong starter life, use short starting cycles (5 seconds maximum).
Then wait one minute before attempting to start again.
note: Moving the Choke Knob too fast could stall the engine.
iMpOrtant: Allow the engine to run at no load for five minutes with no load
after each start-up so that the engine can stabilize.
ITEM 59190
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Page 15
MaintEnancE
SaFEty
SEtup
carBOn MOnOXiDE SHutOFF
DanGEr! tO prEVEnt SEriOuS inJury anD DEatH FrOM carBOn MOnOXiDE inHaLatiOn: the carbon Monoxide sensor is an additional layer of protection only. Do not use the Generator in any area or situation that will allow carbon monoxide to accumulate.
· FLASHING RED LIGHT: Dangerous levels of carbon monoxide gas have built up and generator will shut off. Leave immediately until area has aired out. Move Generator to well-ventilated area before operation.
· FLASHING YELLOW LIGHT: Carbon monoxide sensor malfunction. Sensor needs service. Do not use the Generator until the sensor is working properly. For technical questions, please call 1-888-866-5797. NOTE: Yellow light flashes once after starting to indicate passing selfcheck and is functioning normally.
carbon Monoxide sensor must only be serviced by qualified technician to restore it to original settings. Do not modify or tamper with the carbon Monoxide sensor. not following these instructions can result in death or serious injury due to carbon Monoxide sensor malfunction.
connecting Electrical Loads
Familiarize yourself with the engine controls, power panel and how to start the engine
before using the Generator. Calculate the wattage of the products you will use with
the Generator and verify that the Generator can handle the total load.
WarninG! Connect only properly wired plugs to the Generator. A plug that is spliced onto a
1,040020001,0200
different cord may be hazardous. Only a qualified
electrician should wire a plug onto a cord.
WarninG! Never exceed the rated capacity for this Generator, as serious damage
to the Generator and/ or appliances, tools, and equipment could result from an
overload. Starting and running wattage requirements should always be
calculated when matching
lLSatragretuspt(maWuda (tsdmttoittstubiaosenlnterlaebeulsedSnselntedtaishnrfsatgo- nutrWhpaa,alWn0lt0ltaos0t,a)tdss04),2105,20,40000
this Generator’s wattage capacity to the appliance, tool, or equipment.
Must be Less than
7,000
Must be Less than
8,750
Use the DC12V Receptacle to power 12VDC equipment.
WarninG! tO prEVEnt SEriOuS inJury: Do not charge batteries without a proper
charge controller. Do not overcharge.
a. Connect the items that require the most wattage first.
b. Connect “inductive” load appliances, tools, and equipment next. Inductive
loads are small hand tools and some small appliances.
c. Connect any lights next.
d. Voltage sensitive appliances, tools, and equipment should be the last to be
connected to the Generator. Plug voltage sensitive items such as TVs, DVD
players, microwaves, and cordless telephones into a UL® Listed voltage surge
protector (not included). Then, connect the surge protector into the
Generator.
iMpOrtant! Failure to connect and operate appliances, tools, and equipment in this sequence can cause damage to the Generator, appliances, tools, and equipment and will void the Warranty of this Generator.
note: If Engine speed or voltage fluctuates with a load below the Generator’s running
watts, move the Engine Choke Lever to the
position.
OpEratiOn
MaintEnancE
Page 16
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ITEM 59190
SaFEty
iF any circuit BrEaKErS trip cHEcK tHE FOLLOWinG:
1. Make sure that ALL circuit breakers are reset before starting the
Generator again.
2. Adjust the plugs so the loads are shared across outlet circuits.
to achieve rated output from the Generator, distribute loads over outlets.
Evenly distributed over outlets:
The generator uses a 2-circuit system to supply power to the receptacles. The
loads must be evenly distributed across receptacles to prevent overload on a
single circuit. If the loads being drawn are below the max rated wattage of
the generator, yet the overload light begins blinking or the generator shuts
off, try redistributing plugs across receptacles.
120V Only (3-wire) adaptor cord connected to L14-30 receptacle:
If the overload light begins blinking or the Generator shuts off, too much
wattage is being drawn from one circuit even though the rated wattage of the
Generator has not been reached. If an additional plug is connected to one of
the duplex receptacles, move the plug to the other duplex receptacle. Restart
the Generator.
note: Only half the Generator’s rated wattage, or 3500W, will be delivered
through a 120V (3-wire) adaptor cord. Exceeding this may cause overload.
240V cord connected to L14-30 receptacle:
The 240V cord will draw full wattage from both circuits. If further loads are
possible, distribute them across receptacles.
SEtup
OpEratiOn
MaintEnancE
ITEM 59190
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Page 17
SaFEty
SEtup
calculating total Wattage of Devices used with the Generator
Before using the Generator, check that the products you want to plug into the
unit are below the rated and maximum wattage ratings of the Generator. Use the
Wattage Calculation Table below, and the watts listed on your products, to
help calculate multiple wattage totals.
to use the table:
1. Add up the Running Watts for all items you would like to use at any given
time.
2. Make sure that this total is under the 7,000 running wattage of the
Generator.
3. Find the single highest starting watts for the selected items and add to
the total.
4. Make sure that this total is under the 8,750 max. starting wattage of the
Generator.
5. Plug in and turn on products from largest wattage to smallest.
Wattage calculation table
Equipment
running Watts
total running Watts (must be less than 7,000)
Largest additional Start-up Watts
total Startup Watts needed for all loads (must be less than 8,750)
Example
Equipment
Electric Water Heater (2,000 + 0) Television (400 + 0) Lawn Mower (1,200 +
1,200) Hand Drill (600 + 600)
running Watts
2,000 400 1,200 600
total running Watts (must be less than 7,000)
Largest additional Start-up Watts
total Startup Watts needed for all loads (must be less than 8,750)
4,200 1,200 5,400
A generator that is rated more than the minimum required max. starting watts will last much longer than a generator that only supplies the exact watts needed.
to calculate Wattage Volts and amps can be multiplied together to get watts
(volts x amps = watts).
to calculate additional Start-up Watts (if they are not Listed)
For equipment with a motor: Use the rated watts amount as an estimate of
additional Start-up Watts.
For most lights or heaters: there are no additional start-up watts.
Wattage Estimate charts
note: Wattages listed below are estimates for that type of equipment only.
Check nameplate wattages on all loads before connecting to Generator.
EMErGEncy
Device
Refrigerator/Freezer Radio
running Watts
700 100
additional Start-up Watts 1500 0
JOB SitE
Device
Air Compressor – 1/2 HP Table Saw – 10″ Belt Sander – 3″ Hand Drill – 1/2″
Halogen Work Light Recipricating Saw
running Watts
1000 1700 1200 600 1000 900
additional Start-up Watts 1000 1300 1200 600 0 900
Device
AM/FM Radio Electric Grill Inflator Pump CD/DVD Player Box Fan – 20″ Coffee
Maker
rEcrEatiOn
running Watts
100 1700
50 100 200 600
additional Start-up Watts 0 0 100 0 200 0
HOuSEHOLD
Device
Computer w/ Monitor Electric Clothes Dryer Electric Range Electric Water
Heater Light Bulb – 100 watts Microwave – 1000 watts Sump Pump – 1/2 HP
Television Washing Machine Well Pump – 1/2 HP
running Watts
800 5500 2100 2000 100 1000 1000 400 1100 1000
additional Start-up Watts 0 500 0 0 0 200 1100 0 1100 1000
LaWn & GarDEn
Device
Hedge Trimmer Pressure Washer Lawn Mower Edger
running Watts
400 1200 1200 1000
additional Start-up Watts 400 1200 1200 1000
HEatinG & cOOLinG
Device
Central AC – 10,000 BTU Furnace Fan – 1/2 HP Space Heater Window AC – 10,000
BTU
running Watts
1500 900 1800 1200
additional Start-up Watts 1500 1400 0 600
OpEratiOn
MaintEnancE
Page 18
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ITEM 59190
SaFEty
Stopping the Engine in an Emergency
1. To stop the engine in an emergency, turn the Engine Switch off.
nOticE: Generator shut-off under load may damage the Generator and attached
equipment.
Start
i O
OFF
Stopping the Engine under normal conditions
1. Before turning off the Engine, turn off all electrical loads, then unplug
them.
2. Turn the ESC Switch to off position.
3. Turn the Engine Switch off.
SEtup
OpEratiOn
MaintEnancE
4. Close the Fuel Valve.
ITEM 59190
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Page 19
SaFEty
SEtup
user-Maintenance instructions
procedures not specifically explained in this manual must be performed only by
a qualified technician.
tO prEVEnt SEriOuS inJury FrOM acciDEntaL OpEratiOn: turn the power Switch of
the Generator to its “OFF” position, wait for the engine to cool, and
disconnect the spark plug cap before performing any inspection, maintenance,
or cleaning procedures.
tO prEVEnt SEriOuS inJury FrOM EQuipMEnt FaiLurE: Do not use damaged
equipment. if abnormal noise, vibration, or excess smoking occurs, have the
problem corrected before further use.
Follow all service instructions in this manual. the engine may fail critically
if not serviced properly.
Many maintenance procedures, including any not detailed in this manual, will
need to be performed by a qualified technician for safety. if you have any
doubts about your ability to safely service the equipment or engine, have a
qualified technician service the equipment instead.
cleaning, Maintenance, and Lubrication
note: This maintenance schedule is intended solely as a general guide. If
performance decreases or if equipment operates unusually, check systems
immediately. The maintenance needs of each piece of equipment will differ
depending on factors such as duty cycle, temperature, air quality, fuel
quality, and other factors.
note: The following procedures are in addition to the regular checks and
maintenance explained as part of the regular operation of the engine and
equipment.
procedure
Brush off outside of engine Check engine oil level Check air cleaner Check
deposit cup Change engine oil Clean/replace air cleaner Check and clean spark
plug 1. Check/adjust idle speed 2. Check/adjust valve clearance 3. Clean fuel
tank, strainer
and carburetor 4. Clean carbon build-up from
combustion chamber Replace fuel line if necessary
Before Each use
Monthly or every 20 hr. of use
Every 3 mo. or Every 6 mo. or 50 hr. of use 100 hr. of use
yearly or every 300 hr. of use
*Service more frequently when used in dusty areas. **These items should be serviced by a qualified technician.
Every 2 years
OpEratiOn
MaintEnancE
Page 20
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ITEM 59190
SaFEty
checking and Filling Fuel
WarninG! tO prEVEnt SEriOuS inJury FrOM FirE: Fill the fuel tank in a well-
ventilated area away from ignition sources. if the engine is hot from use,
shut the engine off and wait for it to cool before adding fuel. Do not smoke.
1. Clean the Fuel Cap and the area around it.
2. Unscrew and remove the Fuel Cap.
note: Do not use gasoline containing more than 10% ethanol (E10). Do not use
E85 ethanol.
Engine Oil change
note: Do not use gasoline that has been stored in a metal fuel container or a
dirty fuel container. it can cause particles to enter the carburetor,
effecting engine performance and/or causing damage.
3. If needed, fill the Fuel Tank to about 1 inch under the fill neck with 87
octane or higher unleaded gasoline that has been treated with a fuel
stabilizer additive. Follow fuel stabilizer manufacturer’s recommendations for
use.
4. Replace the Fuel Cap.
5. Wipe up any spilled fuel and allow excess to evaporate before starting
engine. To prevent FIRE, do not start the engine while the smell of fuel hangs
in the air.
cautiOn! Oil is very hot during operation and can cause burns. Wait for engine
to cool before changing oil.
1. Make sure the engine is stopped and is level.
2. Close the Fuel Valve.
3. Place a drain pan (not included) underneath the crankcase’s drain plug.
4. Remove the drain plug and, if possible, tilt the crankcase slightly to
help drain the oil out. Recycle used oil.
note: Do not thread the dipstick in when checking the oil level.
The SAE Viscosity Grade chart shows other viscosities to use in different
average temperatures.
SaE Viscosity Grades
30
10W-30
5. Replace the drain plug and tighten it.
6. Clean the top of the Dipstick and the area around it. Remove the Dipstick
by threading it counterclockwise, and wipe it off with a clean lint free rag.
5W-30
-20 0 20 40 60 80 100°F
average outdoor temperature
8. Thread the dipstick back in clockwise.
Full level
Full level
cautiOn! Do not run the engine with too little oil. The engine will be permanently damaged.
SEtup
OpEratiOn
MaintEnancE
7. Add the appropriate type of oil until the oil level is at the full level.
SAE 10W-30 oil is recommended for general use.
air Filter Element Maintenance
1. Remove the air filter cover and the air filter elements and check for
dirt. Clean as described below.
2. cleaning:
· For “paper” filter elements: To prevent injury from dust and debris, wear
ANSI-approved safety goggles, NIOSH-approved dust mask/respirator, and heavy-
duty work gloves. In a well-ventilated area away from bystanders, use
pressurized air to blow dust out of the air filter. If this does not get the
filter clean, replace it.
· For foam filter elements: Wash the element in warm water and mild detergent
several times. Rinse. Squeeze out excess water and allow it to dry completely.
Soak the filter in lightweight oil briefly, then squeeze out the excess oil.
3. Install the cleaned filter. Secure the Air Cleaner Cover before use.
ITEM 59190
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Page 21
Spark plug Maintenance
SaFEty
1. Disconnect spark plug cap from end of plug. Clean out debris from around
spark plug.
2. Using a spark plug wrench, remove the spark plug.
3. Inspect the spark plug: If the electrode is oily, clean it using a clean,
dry rag. If the electrode has deposits on it, polish it using emery paper. If
the white insulator is cracked or chipped, the spark plug needs to be
replaced.
nOticE: Using an incorrect spark plug may damage the engine. See the
Specifications chart for your Generator for the type and gap required.
4. When installing a new spark plug, adjust the plug’s gap to the
specification on the Specifications chart. Do not pry against the electrode,
the spark plug can be damaged.
5. Install the new spark plug or the cleaned spark plug into the engine.
Gasket-style: Finger-tighten until the gasket contacts the cylinder head, then
about 1/2-2/3 turn more. Non-gasket-style: Finger-tighten until the plug
contacts the head, then about 1/16 turn more.
nOticE: Tighten the spark plug properly. If loose, the spark plug will cause
the engine to overheat. If overtightened, the threads in the engine block will
be damaged.
6. Apply dielectric spark plug boot protector (not included) to the end of
the spark plug and reattach the wire securely.
SEtup
OpEratiOn
Storage
When the equipment is to remain idle for longer than 20 days, prepare the
Engine for storage as follows:
1. cLEaninG: Wait for Engine to cool, then clean Engine with dry cloth.
nOticE: Do not clean using water. The water will gradually enter the Engine
and cause rust damage. Apply a thin coat of rust preventive oil to all metal
parts.
2. FuEL: Gasoline treatment/Draining the Fuel tank To protect the fuel tank
during storage, fill the tank with fresh gasoline that has been treated with a
fuel stabilizer additive. Follow fuel stabilizer manufacturer’s
recommendations for use. Refer to Checking and Filling Fuel Checking and
Filling Fuel on page 11.
Aged gasoline that has not been treated with stabilizer ahead of time must be
safely drained away and not run through the engine.
WarninG! tO prEVEnt SEriOuS inJury FrOM FirE: Fill tank in a well-ventilated
area away from ignition sources. if the engine is hot from use, shut the
engine off and wait for it to cool before adding fuel. Do not smoke.
Draining the carburetor
After closing the Fuel Valve, place an appropriate container under the
Carburetor and carefully remove the Drain Bolt from the bottom of the
Carburetor Bowl, allowing the fuel to drain completely. Replace the Drain Bolt
after draining.
WarninG! to prevent serious injury and fire, close the Fuel Valve before
draining the carburetor.
LuBricatiOn:
a. Change engine oil.
b. Clean out area around spark plug. Remove spark plug and pour one tablespoon
of engine oil into cylinder through spark plug hole.
c. Replace spark plug, but leave spark plug cap disconnected.
d. Pull Starter Handle to distribute oil in cylinder. Stop after one or two
revolutions when you feel the piston start the compression stroke (when you
start to feel resistance).
3. StOraGE arEa: Cover and store in a dry, level, well-ventilated area out of
reach of children. Storage area should also be away from ignition sources,
such as water heaters, clothes dryers, and furnaces. Avoid direct exposure to
rain and sunlight.
nOticE: During extended storage periods the Engine must be started every 3
months and allowed to run for 1520 minutes or the Warranty is VOID.
4. aFtEr StOraGE: Before starting the Engine during or after storage, keep in
mind that untreated gasoline will deteriorate quickly. Drain the fuel tank and
change to fresh fuel if untreated gasoline has been sitting for a month, if
treated gasoline has been sitting beyond the fuel stabilizer’s recommended
time period, or if the Engine does not start.
MaintEnancE
Page 22
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ITEM 59190
SaFEty
SEtup
troubleshooting
problem
Engine will not start
possible causes
probable Solutions
FUEL RELATED:
FUEL RELATED:
1. No fuel in tank or fuel valve closed.
1. Fill fuel tank with fresh 87+ octane stabilizer treated unleaded gasoline and open fuel valve. Do not use gasoline with more than 10% ethanol (E15, E20, E85, etc.).
2. Choke not in CHOKE position, cold engine. 2. Move Choke to CHOKE position.
3. Gasoline with more than 10% ethanol used. 3. Clean out ethanol rich gasoline from fuel
(E15, E20, E85, etc.)
system. Replace components damaged by
ethanol. Use fresh 87+ octane stabilizer
treated unleaded gasoline only.
Do not use gasoline with more than
10% ethanol (E15, E20, E85, etc.).
4. Low quality or deteriorated, old gasoline.
4. Use fresh 87+ octane stabilizer treated unleaded gasoline. Do not use gasoline with more than 10% ethanol (E15, E20, E85, etc.).
5. Carburetor not primed.
5. Pull on Starter Handle to prime.
6. Dirty fuel passageways.
6. Clean out passageways using fuel additive. Heavy deposits may require further cleaning.
7. Carburetor needle stuck. Fuel can be smelled in the air.
7. Gently tap side of carburetor float chamber with screwdriver handle.
8. Too much fuel in chamber. This can be caused by the carburetor needle sticking.
8. Turn Choke to RUN position. Remove spark plug and pull the start handle several times to air out the chamber. Reinstall spark plug and set Choke to CHOKE position.
9. Clogged Fuel Filter.
9. Replace Fuel Filter.
IGNITION (SPARK) RELATED:
IGNITION (SPARK) RELATED:
1. Power Switch at OFF position.
1. Turn Power Switch to ON.
2. Spark plug cap not connected securely.
2. Connect spark plug cap properly.
3. Spark plug electrode wet or dirty.
3. Clean spark plug.
4. Incorrect spark plug gap.
4. Correct spark plug gap.
5. Spark plug cap broken.
5. Replace spark plug cap.
6. Circuit breaker tripped (electric start models only).
6. Reset circuit breaker. Check wiring and starter motor if breaker continues to trip.
7. Incorrect spark timing or faulty ignition system.
7. Have qualified technician diagnose/ repair ignition system.
COMPRESSION RELATED:
COMPRESSION RELATED:
1. Cylinder not lubricated. Problem after long 1. Pour tablespoon of oil into spark
storage periods.
plug hole. Crank engine a few
times and try to start again.
2. Loose or broken spark plug. (Hissing noise 2. Tighten spark plug. If that does not work,
will occur when trying to start.)
replace spark plug. If problem persists,
may have head gasket problem, see #3.
3. Loose cylinder head or damaged head gasket. (Hissing noise will occur when trying to start.)
3. Tighten head. If that does not remedy problem, replace head gasket.
4. Engine valves or tappets mis-adjusted or stuck.
4. Have qualified technician diagnose/ repair ignition system.
ELECTRIC START RELATED:
ELECTRIC START RELATED:
1. No battery or defective battery installed. 1. Install a new battery (see page 10).
2. Battery is low.
2. Charge the battery.
3. Electric start fuse (5A) is blown.
3. Replace fuse with similar size fuse.
OpEratiOn
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ITEM 59190
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Page 23
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troubleshooting (continued)
problem
Engine stops when under heavy load
Engine misfires
possible causes
1. Dirty air filter. 2. Engine running cold.
1. Spark plug cap loose. 2. Incorrect spark plug gap or
damaged spark plug. 3. Defective spark plug cap. 4. Old or low quality
gasoline.
Engine stops suddenly
5. Incorrect compression.
1. Carbon Monoxide level high. Red light on Carbon Monoxide Sensor
illuminates.
2. CO Sensor Alarm flashes yellow continually shortly after starting.
3. CO Sensor Alarm flashes yellow continually after longer period of operation.
4. Fuel tank empty or full of impure or low quality gasoline.
Engine knocks
5. Defective fuel tank cap creating vacuum, preventing proper fuel flow.
6. Faulty magneto. 7. Disconnected or improperly
connected spark plug cap.
1. Old or low quality gasoline.
2. Engine overloaded. 3. Incorrect spark timing, deposit buildup, worn
engine, or other mechanical problems.
Engine backfires 1. Impure or low quality gasoline.
2. Engine too cold.
3. Intake valve stuck or overheated engine.
Product doesn’t have power.
4. Incorrect timing. 1. Product not plugged in properly.
2. Circuit Breaker tripped.
3. GFCI activated.
4. Electronic overload activated. 5. Product needs service.
probable Solutions
1. Clean or replace element. 2. Allow engine to warm up prior
to operating equipment.
1. Check wire connections. 2. Re-gap or replace spark plug.
3. Replace spark plug cap. 4. Use only fresh 87+ octane stabilizer treated
unleaded gasoline. Do not use gasoline with more than 10% ethanol (E15, E20,
E85, etc.). 5. Diagnose and repair compression. (Use Engine will not start:
cOMprESSiOn rELatED section.)
1. Leave area immediately and allow area to ventilate thoroughly. Only
operate generator outside.
2. Carbon monoxide sensor malfunction. Sensor needs service. Call
1-888-866-5797 as soon as possible. Do
not use the Generator until the sensor is working properly.
3. Make sure to operate generator within rated ambient temperature; maintain
minimum 5 ft. clearance from all sides.
4. Fill fuel tank with fresh 87+ octane stabilizer treated unleaded gasoline.
Do not use gasoline with more than 10% ethanol (E15, E20, E85, etc.).
5. Test/replace fuel tank cap.
6. Have qualified technician service magneto. 7. Secure spark plug cap.
1. Fill fuel tank with fresh 87+ octane stabilizer treated unleaded gasoline.
Do not use gasoline with more than 10% ethanol (E15, E20, E85, etc.).
2. Do not exceed equipment’s load rating. 3. Have qualified technician
diagnose
and service engine.
1. Fill fuel tank with fresh 87+ octane stabilizer treated unleaded gasoline.
Do not use gasoline with more than 10% ethanol (E15, E20, E85, etc.).
2. Use cold weather fuel and oil additives to prevent backfiring.
3. Have qualified technician diagnose and service engine.
4. Check engine timing.
1. Turn off and unplug the product, then plug it back in again and turn on.
2. Turn off and unplug product. Reset Circuit Breaker. Plug in product and
turn on.
3. Turn off and unplug product. Test GFCI receptacle. If functioning properly
reset GFCI, plug in product and turn on.
4. Turn off and unplug the product, then press the reset button.
5. Have product repaired.
Follow all safety precautions whenever diagnosing or servicing the equipment or engine.
OpEratiOn
MaintEnancE
Page 24
For technical questions, please call 1-888-866-5797.
ITEM 59190
troubleshooting (continued)
problem
Product begins to operate abnormally.
possible causes
1. Problem with appliance.
2. Rated load capacity exceeded.
probable Solutions
1. Immediately unplug appliance. Have appliance repaired by a qualified
technician, or replace appliance.
2. Lower the number of items plugged into the Generator to stay within the
rated capacity, or use a more powerful generator.
Follow all safety precautions whenever diagnosing or servicing the equipment or engine.
SaFEty
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OpEratiOn
MaintEnancE
ITEM 59190
For technical questions, please call 1-888-866-5797.
Page 25
pLEaSE rEaD tHE FOLLOWinG carEFuLLy
THE MANUFACTURER AND/OR DISTRIBUTOR HAS PROVIDED THE PARTS LIST AND ASSEMBLY
DIAGRAM IN THIS MANUAL AS A REFERENCE TOOL ONLY. NEITHER THE MANUFACTURER OR
DISTRIBUTOR MAKES ANY REPRESENTATION OR WARRANTY OF ANY KIND TO THE BUYER THAT
HE OR SHE IS QUALIFIED TO MAKE ANY REPAIRS TO THE PRODUCT, OR THAT HE OR SHE
IS QUALIFIED TO REPLACE ANY PARTS OF THE PRODUCT. IN FACT, THE MANUFACTURER
AND/OR DISTRIBUTOR EXPRESSLY STATES THAT ALL REPAIRS AND PARTS REPLACEMENTS
SHOULD BE UNDERTAKEN BY CERTIFIED AND LICENSED TECHNICIANS, AND NOT BY THE
BUYER. THE BUYER ASSUMES ALL RISK AND LIABILITY ARISING OUT OF HIS OR HER
REPAIRS TO THE ORIGINAL PRODUCT OR REPLACEMENT PARTS THERETO, OR ARISING OUT
OF HIS OR HER INSTALLATION OF REPLACEMENT PARTS THERETO.
SaFEty
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OpEratiOn
MaintEnancE
record product’s Serial number Here: note: If product has no serial number,
record month and year of purchase instead.
note: Some parts are listed and shown for illustration purposes only, and are
not available individually as replacement parts. Specify UPC 193175459114 when
ordering parts.
Page 26
For technical questions, please call 1-888-866-5797.
ITEM 59190
SaFEty
parts List and Diagram
parts List and Diagram – Wheel Kit
part
Description
1 Sling
2 Pin Shaft
3 Handle Glove
4 Handle Tube Assy
5 Bolt
6 Bolt
7 Seat, Handle Tube Connecting
8 Lock Nut
9 Lock Nut
10 Flat Washer
Qty
part
Description
Qty
1
11 Shaft, Front Wheel
2
1
12 Wheel, Front
2
2
13 Flat Washer
2
1
14 Lock Nut
2
4
15 nut With Flange
2
1
16 nut With Flange
4
1
17 Support, Shock Absorption
2
1
18 Seat, Engine Frame Shock Absorption 2
2
19 Bolt
2
2
2 1
4 3
3
56
8 7
15 16
16
17 18
19
15 16
16
17
18 19
12 11
14 13
9 10
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OpEratiOn
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ITEM 59190
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Page 27
Main parts List
SaFEty
SEtup
part
Description
Qty
1 Bolt
15
2 Starter Assy, Recoil
1
3 Recoil Starter Reel Cover Retainer
1
4 Shroud
1
5 Shroud, Cylinder Body
1
6 Shroud 2, Cylinder Body
1
7 Clip
1
8 Nut, Flywheel
1
9 Pulley,Starter
1
10 Seat, Starter Cup
1
11 Impeller
1
12 Bolt
3
13 Case Subassembly, Magneto Rotor 1
14 Motor Assy,Starting
1
15 Stator Subassembly, Magneto
1
16 Seal, Oil
1
17 Trigger Assy.
1
18 Clamp, Magneto Wiring
1
19 Bolt
1
20 Bolt
2
21 Crankcase Subassembly.
1
22 Tube, Oil Drain
1
23 Bolt, Drain Plug
1
24 Washer, Flat
1
25 Bolt
2
26 Sensor, Engine Oil
1
27 Nut
1
28 Bolt
2
29 Tappet, Valve
2
30 Valves Set
1
31 Guide, Seal
1
32 Retainer, Valve Spring
2
33 Spring, Valve
2
34 Retainer, Exhaust Valve
1
35 Rotator, Valve
1
36 Seat, Valve Spring
1
37 Camshaft Assy.
1
38 Lifter Subassembly, Valve
2
39 Plate Subassembly, Lifter Stopper
1
40 Bolt, Rocker Shaft
2
41 Rocker, Valve
2
42 Nut, Valve Adjusting
2
43 Nut, Valve Lock
2
44 Pin
2
45 Gasket, Cylinder Head
1
46 Head Subassembly, Cylinder
1
47 Stud
2
48 Stud
2
49 Bolt, Cylinder Head
4
50 Plug, Spark
1
51 Gasket, Cylinder Head Cover
1
52 Cover Subassembly, Cylinder Head 1
53 Cylinder Head Bolt Gasket Set
1
54 Bolt, Cylinder Head
1
55 Tube, Breather
1
56 Gasket, Inlet
1
57 Plate, Carburetor Insulator
1
58 Gasket, Carburetor
1
59 Carburetor Assy.
1
60 Gasket, Air Cleaner
1
61 Cleaner Comp, Air
1
part
Description
Qty
62 Nut
2
63 Bearing, Deep Groove Ball
2
64 Coil, Ignition
1
65 Bolt
2
66 Rod, Connecting
1
67 Clip, Piston Pin
2
68 Piston
1
69 Pin, Piston
1
70 Ring Assy, Piston
1
71 Crankshaft Assy.
1
72 Shaft Assy, Balancing
1
73 Gasket, Crankcase
1
74 Pin
2
75 Dipstick Subassembly, Oil
1
76 Cover, Crankcase
1
77 Bolt
7
78 Bearing, Deep Groove Ball
1
79 Cap
1
80 Cover, Fuel Tank
1
81 Chain Proof Off, Fuel Tank Cover
1
82 Anti-Off Chain Clip
1
83 Strainer, Fuel
1
84 Bolt
2
85 Leveler Assy, Oil
1
86 Bolt
4
87 Washer, Flat
4
88 Bush
4
89 Sleeve, Fuel Tank Rubber
4
90 Tank, Fuel
1
91 Valve, One Way
1
92 Outlet Subassembly, Fuel Tank Oil
1
93 Clamp
1
94 Tube, Fuel
1
95 Clamp
2
96 Tube, Fuel
1
97 Clamp
1
98 Seat, Fuel Cock
1
99 Cock Assy, Fuel
1
100 Hose, Fuel Steam Rubber
1
101 Hose, Air Cleaner Rubber
1
102 Collector, Fuel Steam
1
103 Nut
2
104 Bolt
2
105 Muffler Assy.
1
106 Gasket, Exhaust Outlet
1
107 Nut
2
108 Cover, Muffler Outer
1
109 Bolt
3
110 Bolt
3
111 Invertor Mounting Rack
1
112 Invertor Mounting Rack
1
113 Frame Assy, Engine
1
114 Protective Rubber Sleeve
2
115 Bolt
1
116 Clip
1
117 Nut
1
118 Nut
8
119 Bolt
4
120 Cushion, Engine Frame
4
121 Engine Fixed Bottom Plate
1
122 Engine Fixed Bottom Plate
1
OpEratiOn
MaintEnancE
Page 28
For technical questions, please call 1-888-866-5797.
ITEM 59190
SaFEty
Main parts List (continued)
part
Description
Qty
123 Nut
4
124 Support, Atr Cleaner
1
125 CO Sensor
1
126 Hexalobular Socket Pan Head Screw 2
127 Clamp, Battery
1
128 Bolt
2
129 Battery
1
130 Wire, Anode
1
131 Wire, Cathode
1
132 Thermal Baffle
1
133 Seat, Panel
1
134 Bolt
4
135 Large Washer – Grade A
4
136 Bolt
4
137 Washer, Flat
4
138 Invertor
1
139 Panel Subassembly, Control
1
140 Protector, Overcurrent
2
141 Bridge, Rectification
1
142 Timer
1
143 Ignitor
1
144 Choke
1
part
Description
Qty
145 Switch Subassembly
1
146 Switch Subassembly
1
147 Indicator
1
148 Protector, Overcurrent
1
149 Socket Subassembly, D.C
1
150 Socket Subassembly, D.C
1
151 Breaker, Double-Pole
1
152 Socket Subassembly, Power Supply 1
153 Rain Cover Receptacle
1
154 Socket Subassembly, Power Supply 2
155 Rain Cover Receptacle
2
156 Terminal Subassembly, Grounding
1
Cross-Recessed Small Pan
157 Head Screw, Spring Washer
6
And Flat Washer Assembly
158 Transportation Support Block
2
159 Bolt
4
160 Nut
4
161 Bolt
1
162 Control Panel Wiring Harness
1
163 CO Controller
1
SEtup
OpEratiOn
MaintEnancE
ITEM 59190
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Page 29
Main assembly Diagram
SaFEty
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OpEratiOn
MaintEnancE
Page 30
For technical questions, please call 1-888-866-5797.
ITEM 59190
Main assembly Diagram
SaFEty
SEtup
OpEratiOn
MaintEnancE
ITEM 59190
For technical questions, please call 1-888-866-5797.
Page 31
SaFEty
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Warranties
Limited 90 Day Warranty (retail)
Harbor Freight Tools Co. makes every effort to assure that its products meet
high quality and durability standards, and warrants to the original purchaser
that this product is free from defects in materials and workmanship for the
period of 90 days from the date of purchase. This warranty does not apply to
damage due directly or indirectly, to misuse, abuse, negligence or accidents,
repairs or alterations outside our facilities, criminal activity, improper
installation, normal wear and tear, or to lack of maintenance. We shall in no
event be liable for death, injuries to persons or property, or for incidental,
contingent, special or consequential damages arising from the use of our
product. Some states do not allow the exclusion or limitation of incidental or
consequential damages, so the above limitation of exclusion may not apply to
you. THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR
IMPLIED, INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS, EXCEPT FOR
THE EMISSIONS CONTROL SYSTEM WARRANTY BELOW.
To take advantage of this warranty, the product or part must be returned to us
with transportation charges prepaid. Proof of purchase date and an explanation
of the complaint must accompany the merchandise. If our inspection verifies
the defect, we will either repair or replace the product at our election or we
may elect to refund the purchase price if we cannot readily and quickly
provide you with a replacement. We will return repaired products at our
expense, but if we determine there is no defect, or that the defect resulted
from causes not within the scope of our warranty, then you must bear the cost
of returning the product.
This warranty gives you specific legal rights and you may also have other
rights which vary from state to state.
Emissions control System Warranty
The California Air Resources Board and Harbor Freight Tools (HFT) are pleased
to explain the emissions control system warranty on your [Model Year] Small
Off-Road Engine, in addition to the Retail Warranty above. In California, new
equipment that uses small off-road engines must be designed, built, and
equipped to meet the State’s stringent anti-smog standards. HFT warrants that
the emissions control system on your engine will be free from defects in
material and workmanship for two (2) years, provided there has been no abuse,
neglect, or improper maintenance of your engine. HFT also warrants that the
emissions control system on your engine is designed, built, and equipped so
that it conforms to the United States Environmental Protections Agency’s (EPA)
emissions requirements in effect at the time of manufacture.
Your emissions control system may include parts such as the carburetor or
fuel-injection system, the ignition system, catalytic converter, fuel tanks,
fuel lines, fuel caps, valves, canisters, vapor hoses, clamps, connectors, and
other emissions-related assemblies.
Where a warrantable condition exists, HFT will repair or replace, at our
option, your engine if at no cost to you, including diagnosis, parts and
labor.
ManuFacturEr’S Warranty cOVEraGE
This emissions control system is warranted for two years. If any emission-
related part on your engine is defective, the part will be repaired or
replaced by HFT.
OWnEr’S Warranty rESpOnSiBiLitiES
As the engine owner, you are responsible for the performance of the required
maintenance listed in your Owner’s Manual.
As the engine owner, you should however be aware that HFT may deny you
warranty coverage if your engine or a part has failed due to abuse (including
failure to follow the fuel use instructions contained in this manual),
neglect, improper maintenance, or unapproved modifications.
You are responsible for contacting HFT as soon as the problem exists in order
to obtain warranty repair or replacement, by doing either of the following:
(a) contact HFT product support at
1-888-866-5797 or
[email protected]; or (b) bring the to your nearest Harbor
Freight Tools retail store. The nearest Harbor Freight Tools retail store can
be found on the internet at http://www.harborfreight.com. The warranty repairs
or replacement should be completed in a reasonable amount of time, not to
exceed 30 days. If you have a question regarding your warranty coverage, you
should contact HFT product support at
1-888-866-5797 or
[email protected].
OpEratiOn
MaintEnancE
Page 32
For technical questions, please call 1-888-866-5797.
ITEM 59190
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GEnEraL EMiSSiOnS Warranty cOVEraGE
a) The warranty period begins on the date the engine or equipment is delivered to an ultimate purchaser. The warranty period is two years.
b) HFT warrants to the initial owner and each subsequent owner that the engine is:
1. Designed, built, and equipped so as to conform with all applicable regulations adopted by the Air Resources Board; and
2. Free from defects in materials and workmanship that causes the failure of a warranted part for a period of two years.
c) The warranty on emissions-related parts is as follows:
1. Any warranted part that is not scheduled for replacement as required maintenance in the written instructions provided, is warranted for the warranty period stated above. If any such part fails during the period of warranty coverage, it will be repaired or replaced HFT. Any such part repaired or replaced under the warranty will be warranted for the remaining warranty period.
2. Any warranted part that is scheduled only for regular inspection in the written instructions is warranted for the warranty period stated above. Any such part repaired or replaced under warranty will be warranted for the remaining warranty period.
3. Any warranted part that is scheduled for replacement as required maintenance in the written instructions will be warranted for the period of time prior to the first scheduled replacement point for that part. If the part fails prior to the first scheduled replacement, the part will be repaired or replaced by HFT. Any such part repaired or replaced under warranty will be warranted for the remainder of the period prior to the first scheduled replacement point for the part.
4. Repair or replacement of any warranted part under the warranty will be performed at no charge to the owner at a retail store or by HFT paying for shipping the product for repair.
5. Notwithstanding the provisions herein, warranty services or repairs will be provided at all retail stores or by contacting HFT product support.
6. The owner will not be charged for diagnostic labor that leads to the determination that a warranted part is in fact defective, provided that such diagnostic work is performed at a retail store.
7. HFT is liable for damages to other engine components proximately caused by a failure under warranty of any warranted part.
8. Throughout the emissions warranty period stated above, HFT will maintain a supply of warranted parts sufficient to meet the expected demand for such parts.
9. Any replacement part may be used in the performance of any warranty maintenance or repairs and will be provided without charge to the owner. Such use will not reduce the warranty obligations of HFT.
10. Add-on or modified parts that are not approved by HFT may not be used. The use of any non-exempted add-on or modified parts will be grounds for disallowing a warranty claim. HFT is not liable to warrant failures of warranted parts caused by the use of a non-exempted add-on or modified part.
d) Emission Warranty Parts List.
1. Fuel Metering System
4. Catalyst System (if so equipped)
a. Carburetor and its internal parts (and/or pressure regulator or fuel
injection system).
b. Fuel tank. c. Cold start enrichment system. d. Air/fuel ratio feedback and
control system. 2. Air Induction System a. Controlled hot air intake system.
b. Intake manifold. c. Air filter. 3. Ignition System a. Spark plugs. b.
Magneto ignition system. c. Spark advance/retard system.
a. Exhaust pipe stud/exhaust manifold. b. Thermal reactor. c. Catalytic
converter (if so equipped). 5. Particulate Controls a. Traps, filters,
precipitators, and any other
device used to capture particulate emissions. 6. Miscellaneous Items Used in
Above Systems
a. Vacuum, temperature and time sensitive valves and switches.
b. Hoses, belts, connectors, and assemblies. 7. Evaporative Emission Control
System
a. Fuel tank. b. Fuel caps, valves, canisters, filters, vapor hoses,
clamps, connectors, belts, and assemblies.
HFT provides with each product written instructions for the maintenance and use of the product by the owner.
OpEratiOn
MaintEnancE
ITEM 59190
For technical questions, please call 1-888-866-5797.
Page 33
MaintEnancE
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SaFEty
Page 34
For technical questions, please call 1-888-866-5797.
ITEM 59190
ITEM 59190
For technical questions, please call 1-888-866-5797.
Page 35
MaintEnancE
OpEratiOn
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SaFEty
26677 agoura road · calabasas, ca 91302 · 1-888-866-5797